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SECTION INDEX
SERVICE
MANUAL FRONT MATTER 0A
GENERAL INFORMATION 0B
MATIZ
(MY2003) ENGINE 1
SUSPENSION 2
FOREWORD DRIVELINE/AXLE 3
This manual includes procedure for maintenance,
adjustment, service operation and removal and
installation of components. BRAKES 4
HVAC
(HEATING, VENTILATION, 7
AND AIR CONDITIONING)
RESTRAINTS 8
DAEWOO MOTOR CO., LTD.
INCHON, KOREA
BODY AND ACCESSORIES 9
h a n g e Vi h a n g e Vi
XC e XC e
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ENGINE
CONTENTS
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SUSPENSION
CONTENTS
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DRIVELINE/AXLE
CONTENTS
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BRAKES
CONTENTS
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TRANSAXLE
CONTENTS
SECTION 5C CLUTCH
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STEERING
CONTENTS
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CONTENTS
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RESTRAINTS
CONTENTS
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CONTENTS
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PD
1A – 2 GENERAL ENGINE INFORMATION
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DESCRIPTION AND SYSTEMOPERATION
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CLEANLINESS AND CARE may result in damage to wire harness or other electrical
parts.
An automobile engine is a combination of many ma-
chined, honed, polished and lapped surfaces with toler-
ances that are measured in the ten–thousandths of an ON-ENGINE SERVICE
inch. When any internal engine parts are serviced, care Caution: Disconnect the negative battery cable be-
and cleanliness are important. A liberal coating of en- fore removing or installing any electrical unit, or
gine oil should be applied to friction areas during assem- when a tool or equipment could easily come in con-
bly, to protect and lubricate the surfaces on initial tact with exposed electrical terminals. Disconnect-
operation. Proper cleaning and protection of machined ing this cable will help prevent personal injury and
surfaces and friction areas is part of the repair proce- damage to the vehicle. The ignition must also be in
dure. This is considered standard shop practice even if B unless otherwise noted.
not specifically stated.
Notice: Any time the air cleaner is removed, the intake
Whenever valve train components are removed for ser-
opening should be covered. This will protect against ac-
vice, they should be kept in order. They should be
installed in the same locations, and with the same mat- cidental entrance of foreign material, which could follow
the intake passage into the cylinder and cause exten-
ing surfaces, as when they were removed. Battery
sive damage when the engine is started.
cables should be disconnected before any major work is
performed on the engine. Failure to disconnect cables
PD
GENERAL ENGINE INFORMATION 1A – 3
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COMPONENT LOCATOR
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D102A401
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1A – 4 GENERAL ENGINE INFORMATION
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ENGINE COMPARTMENT (EURO III)
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MAA1A010
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GENERAL ENGINE INFORMATION 1A – 5
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DIAGNOSTIC INFORMATION PROCEDURE
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GENERAL DIAGNOSIS
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Condition Probable cause Correction
Hard Starting (With Malfunction of D Faulty fuse. D Replace the fuse.
normal cranking) Ignition System
D Faulty spark plug. D Clean, adjust the plug gap or
replace.
D Electric leakage at the high D Replace the cable.
tension cable.
D Poor connection of the high D Replace the cable or wires.
tension cable or lead wires.
D Worn distributor cap or D Replace or clean the
accumulated carbon in the distributor cap.
distributor cap.
D Damaged distributor rotor or D Replace the rotor or the cap.
cap.
D Improper ignition timing. D Adjust the ignition timing.
D Faulty ignition coil. D Replace the ignition coil.
Malfunction of Fuel D Lock of fuel in the fuel tank. D Feed the fuel.
System
D Dirty or clogged fuel filter. D Replace the filter.
D Clogged fuel pipe. D Clean the fuel pipe.
D Malfunction of the fuel pump. D Replace the fuel pump.
D Malfunction of the fuel D Replace the injector.
injector.
D The foreign material in the D Clean the fuel tank.
fuel tank.
Decline of D Poor tightening spark plug. D Tighten to the specified
Compression torque.
Pressure
D Cracked cylinder head D Replace the gasket.
gasket.
D Inadequate the valve D Adjust the clearance.
clearance.
D Leakage of the valve D Repair the valve.
clearance.
D Interference of the valve D Replace the valve or the
stem. valve guide.
D Low elasticity or damage of D Replace the valve spring.
the valve spring.
D Abnormal interference of D Replace the piston ring.
pistons and cylinders.
D Excessive wear of pistons, D Replace the ring or the
rings, or cylinders. piston and boring or replace
the cylinder.
PD
1A – 6 GENERAL ENGINE INFORMATION
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GENERAL DIAGNOSIS (Cont’d)
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Condition
Hard Starting (With Others
Probable cause
D Broken timing belt.
Correction
D Replace the belt.
normal cranking)
D Malfunction of Positive D Check and replace Positive
Crankcase Ventilation (PCV) Crankcase Ventilation (PCV)
valve. valve if needed.
D Loosening, damage or D Connect the hose correctly
leakage of the vacuum hose. or replace it.
D Leakage of intake system. D Replace intake system.
Lack of Engine Power Decline of D Refer to “Page 1A–5”. D Refer to “Page 1A–5”.
Compression
Pressure
Malfunction of D Improper ignition timing. D Adjust the ignition timing.
Ignition System
D Faulty spark plug. D Adjust or replace the spark
plug.
D Malfunction of the distributor. D Repair or replace the
distributor. Check the rotor.
D Electric leakage or poor D Connect the cable correctly
connection of the high or replace it.
tension cable.
Malfunction of D Clogged fuel pipe. D Clean the pipe.
Fuel System
D Clogged or contaminated D Replace the filter.
fuel filter.
Others D Clogged exhaust system. D Check and repair the
system.
D Clogged or contaminated air D Clean or replace the air
cleaner element. cleaner element.
D Leak of the intake manifold D Replace the gasket.
gasket.
D Dragging brakes. D Repair or replace the
brakes.
D Slipping clutch. D Adjust or replace the clutch.
Rough Engine Idling Decline of D Refer to “Page 1A–5”. D Refer to “Page 1A–5”.
Compression
Pressure
Malfunction of D Clogged fuel pipe. D Clean the pipe.
Fuel System
D Clogged or contaminated D Replace the filter.
fuel filter.
D Malfunction of the fuel D Replace the regulator.
pressure regulator.
Malfunction of D Malfunction of the spark D Adjust or replace the spark
Ignition System plug. plug.
D Electric leakage or poor D Connect the cable correctly
connection of the high or replace it.
tension cable.
D Worn distributor cap terminal D Replace or clean the
or accumulated carbon in distributor cap.
the distributor cap.
PD
GENERAL ENGINE INFORMATION 1A – 7
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GENERAL DIAGNOSIS (Cont’d)
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Condition
Rough Engine Idling Malfunction of
Probable cause
D Loosening or damage of the
Correction
D Replace the rotor or cap.
Ignition System distributor rotor or cap.
D Poor ignition timing. D Adjust the ignition timing.
D Malfunction of the ignition D Replace the ignition coil.
coil.
Others D Clogged or contaminated air D Clean or replace the air
cleaner element. cleaner element.
D Leak of the intake manifold D Replace the gasket.
gasket.
D Malfunction of Positive D Check the valve or replace it
Crankcase Ventilation (PCV) if needed.
valve.
D Poor connection or damage D Connect the hose correctly
or leakage of the vacuum or replace it.
hose.
Engine Hesitate (Upon Decline of D Refer to “Page 1A–5”. D Refer to “Page 1A–5”.
pressing accelerating Compression
pedal, the engine Pressure
makes delayed
response. This Malfunction of D Poor ignition timing. D Adjust the ignition timing.
situation is remarkable Ignition System
D Poor spark plug or poor D Replace the plug or adjust
when cruising or adjustment of the plug gap. the gap.
starting.)
D Electric leakage or poor D Connect the cable correctly
connection of the high or replace it.
tension cable.
Others D Malfunction of the air cleaner D Clean or replace the air
system. cleaner system.
D Leak of the intake manifold D Replace the gasket.
gasket.
Engine Surging Decline of D Refer to “Page 1A–5”. D Refer to “Page 1A–5”.
(Engine power makes Compression
fluctuation in a fixed Pressure
speed and speed
changes without Malfunction of D Clogged fuel pipe. D Clean the pipe.
operating the Fuel System
D Clogged or contaminated D Replace the filter.
accelerating pedal.) fuel filter.
D Malfunction of the fuel D Replace the fuel pressure
pressure regulator. regulator.
Malfunction of D Malfunction of the spark D Adjust or replace the spark
Ignition System plug. plug.
D Electric leakage or poor D Connect the cable correctly
connection of the high or replace it.
tension cable.
D Worn distributor cap terminal D Clean or replace the
or accumulated carbon in distributor cap.
the distributor cap.
D Loosening or damage of the D Replace the distributor rotor
distributor rotor or the cap. or the cap.
D Poor ignition timing. D Adjust the ignition timing.
PD
1A – 8 GENERAL ENGINE INFORMATION
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GENERAL DIAGNOSIS (Cont’d)
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Condition Probable cause Correction
Engine Surging Others D Leak of the intake manifold D Clean or replace the gasket.
(Engine power makes gasket.
fluctuation in a fixed
speed and speed
changes without D Leakage of the vacuum hose. D Connect the hose correctly
operating the or replace it.
accelerating pedal.)
Excessive Detonation Overheated D Refer to “Overheat” in this D Refer to “Overheat” in this
(According to the Engine page. page.
opening range of
throttle valve, Malfunction of D Abnormal spark plug. D Replace the spark plug.
knocking sound of Ignition System
metallic is made with D Poor ignition timing. D Adjust the ignition timing.
abnormal explosion.) D Electric leakage or poor D Connect the cable correctly
connection of the high tension or replace it.
cable.
Malfunction of D Clogged or contaminated fuel D Clean or replace the fuel
Fuel System filter and fuel pipe. filter and the fuel pipe.
Others D Leak of the intake manifold D Replace the gasket.
gasket.
D Excessive carbon deposit due D Remove the carbon.
to abnormal combustion.
Overheat Malfunction of D Lack of coolant. D Refill coolant.
Cooling System
D Malfunction of the thermostat. D Replace the thermostat.
D Malfunction of the cooling fan. D Check or replace the cooling
fan.
D Poor water pump D Replace the pump.
performance.
D Clogged or leaky radiator. D Clean, repair or replace the
radiator.
Malfunction of D Poor engine oil. D Replace engine oil with the
Lubrication specified one.
System
D Blocking oil filter or strainer. D Clean or replace the oil filter
or the strainer.
D Lack of engine oil. D Refill oil.
D Poor oil pump performance. D Replace or repair the pump.
D Leakage of oil. D Repair.
Other D Damaged cylinder head D Replace the gasket.
gasket.
Poor Fuel Decline of D Refer to “Page 1A–5”. D Refer to “Page 1A–5”.
Consumption Compression
Pressure
Malfunction of D Leakage of the fuel tank or D Repair or replace the fuel
Fuel System the fuel pipe. tank or the fuel pipe.
PD
GENERAL ENGINE INFORMATION 1A – 9
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GENERAL DIAGNOSIS (Cont’d)
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Poor Fuel
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Condition
Malfunction of
Probable cause
D Improper ignition timing.
Correction
D Adjust the ignition timing.
Consumption Ignition System
D Abnormal spark plug D Replace the plug.
(Excessive carbon deposit,
inadequate gap, burnt
electrode).
D Electric leakage or poor D Connect the cable normally
connection of the high or replace it.
tension cable.
Malfunction of D Malfunction of the D Replace the thermostat.
Cooling System thermostat.
Others D Improperly installed valve. D Repair or replace the valve.
D Slipping clutch. D Repair or replace the clutch.
D Low pressure of tires. D Adjust the pressure of tires.
Excessive Leakage of D Loosened oil drain plug. D Tighten the plug.
Consumption of Engine Oil
Engine Oil D Loosened oil pan bolt. D Tighten the bolt.
D Loosened oil filter. D Tighten the filter.
D Loosened oil pressure D Tighten the switch.
switch.
D Leakage of camshaft front oil D Replace the seal.
seal.
D Leakage of crankshaft front D Replace the seal.
oil seal.
D Leakage at the cylinder head D Replace the gasket.
cover gasket.
D Damage of the cylinder head D Replace the gasket.
gasket.
Oil Mixing in D Stuck piston ring. D Remove carbon and replace
Combustion the ring.
Chamber
D Worn piston or cylinder. D Replace the piston or the
cylinder.
D Worn piston ring or ring D Replace the piston or ring.
groove.
D Inadequate position of the D Adjust the position.
piston ring cutting part.
D Abrasion or damage of the D Replace the valve system.
valve system.
Low Oil Pressure Malfunction of D Inadequate oil viscosity. D Replace with the specified
Lubrication one.
System
D Loosening of the oil pressure D Tighten the switch.
switch.
D Lack of engine oil. D Refill oil.
D Blocking oil strainer. D Clean the strainer.
PD
1A – 10 GENERAL ENGINE INFORMATION
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GENERAL DIAGNOSIS (Cont’d)
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Condition
Low Oil Pressure Malfunction of
Probable cause
D Lowered function of the oil
Correction
D Replace the pump.
Lubrication pump.
System
D Abrasion or damage of the D Replace the valve.
oil pump relief valve.
Engine Noise Valve Noise D Inadequate valve clearance. D Adjust the valve clearance.
D Abrasion of valve stem or D Replace the valve stem or
guide. the guide.
D Weak valve spring. D Replace the spring.
Piston, Ring, D Abrasion of the piston, the D Boring the cylinder or
Cylinder Noise ring or the cylinder. replace the piston, the ring
or the cylinder.
Connecting Rod D Abrasion of the connecting D Replace the bearing.
Noise rod bearing.
D Loosened the connecting rod D Tighten to the specified
nut. torque.
Crankshaft D Abrasion of the crankshaft D Replace the bearing.
Noise bearing.
D Abrasion of the crankshaft D Grind or replace the
journal. crankshaft journal.
D Loosened bearing cap bolt. D Tighten to the specified
torque.
D Excessive clearance of the D Adjust or replace.
crankshaft thrust bearing.
D Low oil pressure. D Refer to “Low Oil Pressure”
in this section.
PD
GENERAL ENGINE INFORMATION 1A – 11
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CHECKING ENGINE FLUID LEVEL 3. Remove the oil drain plug (c) and draw oil off.
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Check the engine fluid level or condition. If needed, refill
or replace the oil.
Check the engine oil level within engine normal operat-
ing temperature as follows ;
1. After stopping the engine, wait for a few minutes to
accumulate oil into the oil pan.
2. After pulling out the oil level gauge (a), check the oil
level.
3. Clean the oil level gauge and insert the gauge into
guide.
4. After pulling out the oil level gauge again, recheck the
oil level and insert the gauge into guide again.
Important: Oil level should be between “MIN” mark and
“MAX” mark.
5. If oil level is below the “MIN” mark, refill engine oil as
much as the demanded quantify.
D102A302
Important: If checking oil level under the engine cold
condition, oil is not accumulated into oil pan quickly and 4. After drawing oil completely, tighten the oil drain plug
correct level checking can not be performed. Therefore, to 30–40 NSm (22–30 lb-ft).
wait until temperature reaches the normal operating
5. Replace the oil filter using the oil filter wrench
condition and check the engine oil level.
09915–47341 (d).
D Remove the air cleaner/resonator/snorkel as-
sembly.
D After removing the bolts, remove the heat
shield.
D Loosen the power steering pump cap screw and
pull the power steering hose into the front.
D Remove the oil filter.
Important: Whenever changing engine oil, replace the
oil filter. When replacing new oil filter, apply engine oil on
oil filter sealing.
D102A301
PD
1A – 12 GENERAL ENGINE INFORMATION
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CHECKING ENGINE TIMING BELT
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After checking the timing belt for looseness, crack, wear
or tension, replace the belt if necessary.
D102A305
D102A304
D102A306
PD
GENERAL ENGINE INFORMATION 1A – 13
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CHECKING AIR CLEANER ELEMENT CHECKING FUEL SYSTEM
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If the air cleaner element becomes dirty, engine efficien- Check the fuel system as follows ;
cy could be deteriorated. D Check the fuel line or line connection portion for dam-
Be sure to check the element often. age or leakage.
Especially, if a vehicle frequently runs on a dusty road, D Check the fuel hose surface for damage.
check and replace the element often. D Check the fuel cap for looseness.
PD
1A – 14 GENERAL ENGINE INFORMATION
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SPECIFICATIONS
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GENERAL SPECIFICATIONS
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ÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑÑ Application Description
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Maximum Speed 144 km/h (90 mph)
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Vehicle Capacity Gradeability 0.420 tan θ
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Minimum Turning Radius
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Bore × Stroke
4.5 m (14.8 ft)
68.5 × 72.0 mm (2.70 × 2.83 inch)
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Displacement 796 cm3 (48.6 in3)
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Compression Ratio 9.3 : 1
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Maximum Power 37.5 KW (6,000 rpm)
Engine Information
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Maximum Torque 68.6 NSm (50.59 lb-ft) (at 4,600 rpm)
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Ignition Timing (Ignition Sequence) 5_ BTDC (1–3–2) / 10_ BTDC (1–3–2)
1,000 ± 50 rpm
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Air Conditioning System (ON)
Idle Speed
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Air Conditioning System (OFF) 950 rpm
Engine Overhead Cam L–3
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Ignition Type
Direct Ignition System (DIS) /
High Energy Ignition (HEI)
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Distributor Optical Sensor Type
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Starter
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Spark–Plug
Unleaded
SD 80
BPR5EY–11, RN9YC4, WR8DCX
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Leaded BPR5EY, RN9YC, WR8DC
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Fuel Injection Type MPI
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Fuel Pump Electric Motor Pump
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Engine Part Type Fuel Filter Cartridge
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Lubricating Type Forced Feed Type
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Oil Pump Rotary Pump Type
Cooling Type Forced Water Circulation
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Radiator Cross – Flow
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Water Pump
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Thermostat
Centrifugal
Pellet Type
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Air Cleaner Element Non Woven Fablic
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Muffler Catalytic Converter, Closed Circuit
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Battery
Engine Oil
MF
SJ Grade
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Engine Part SAE 5W30, SAE 10W30, SAE 15W40
Capacity
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Refrigerant Four Seasons
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Engine Disassembly 3.0 L (3.17 qt)
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Oil Change (Including filter) 2.7 L (2.85 qt)
Engine Oil
Oil Change (Not including filter) 2.5 L (2.64 qt)
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ÑÑÑÑÑÑÑÑÑÑÑÑÑ Oil Level Gauge 1 L (1.06 qt) (MIN to MAX)
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Coolant 3.8 L (4.02 qt)
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Engine Information Battery 12V–35 AH, 246 CCA
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Generator 65 A
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Starter
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Fuel Pump
Output Pressure 380 kPa (55.1 Psi)
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Fuel Tank Capacity 35 L (9.2 gal), 38 L (10 gal)
PD
GENERAL ENGINE INFORMATION 1A – 15
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ENGINE PERFORMANCE CURVE
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D Maximum Power
: 51 PS (37.5 KW)
(at 6,000 rpm)
D Maximum Torque
: 7 KgSm (68.6 NSm)
(at 4,600 rpm)
D12A101A